Part No. 05144SL Rev. A Service Manual Line Painter 1200 Preface The purpose of this publication is to provide the service technician with information for troubleshooting, testing and repair of major systems and components on the Line Painter 1200. REFER TO THE OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Space is provided in Chapter 2 of this book to insert the Operator’s Manuals and Parts Catalogs for your machine.
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Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 2 Paint Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 3 Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 8 General Information . . . . . . . . . . . . . . . . . . . . . . . . 5 – 9 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 10 Service and Repairs . . . . . . . . . . . .
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Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
Safety Instructions The Line Painter 1200 is designed and tested to offer safe service when operated and maintained properly. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine. Improper use or maintenance of the machine can result in injury or death.
1. Before servicing or making adjustments, position machine on a level surface and apply parking brake to prevent machine from moving. 8. Do not overspeed the engine by changing governor setting. To assure safety and accuracy, check maximum engine speed with a tachometer. 2. Disconnect the spark plug wire from the spark plug and position the wire away from the spark plug to ensure that the engine will not start accidentally. 9. Shut engine off before checking or adding oil to the engine crankcase. 3.
Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Line Painter 1200. If any decal becomes illegible or damaged, install a new decal. Part numbers for replacement decals are listed in your Parts Catalog. Order replacement decals from your Authorized Toro Distributor.
Chapter 2 Product Records and Maintenance PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions Product Records and Maintenance Page 2 – 2 Line Painter 1200
Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual. These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual.
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Thread Size # 6 – 32 UNC Grade 1, 5 & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems** with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in–lb in–lb N–cm 10 + 2 13 + 2 147 + 23 # 6 – 40 UNF # 8 – 32 UNC 13 + 2 25 + 5 282 + 56 # 8 – 36 UNF # 10 – 24 UNC 18 + 2 30 + 5 339 + 56 # 10 – 32 UNF SAE Grade 5 Bolts, Screws, Studs & Sems** with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts)
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 6 in–lb 644 + 68 N–cm 78 + 8 in–lb 881 + 90 N–cm M6 X 1.0 96 + 10 in–lb 1085 + 113 N–cm 133 + 14 in–lb 1503 + 158 N–cm M8 X 1.25 19 + 2 ft–lb 26 + 3 N–m 28 + 3 ft–lb 38 + 4 N–m M10 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Thread Size Square Head Hex Socket 1/4 – 20 UNC 140 + 20 in–lb 73 + 12 in–lb 5/16 – 18 UNC 215 + 35 in–lb 145 + 20 in–lb 3/8 – 16 UNC 35 + 10 ft–lb 18 + 3 ft–lb 1/2 – 13 UNC 75 + 15 ft–lb 50 + 10 ft–lb Recommended Torque** 7/16 – 20 UNF Grade 5 65 + 10 ft–lb 88 + 14 N–m 1/2 – 20 UNF Grade 5 80 + 10 ft–lb 108 + 14 N–m M12 X 1.25 Class 8.
Chapter 3 Gasoline Engine Table of Contents Line Painter 1200 2 3 4 4 5 5 6 8 Page 3 – 1 Gasoline Engine INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . Fuel Shut–off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . Cooling System . . . . . . . . . . . . . . . . . . . . . .
Introduction This Chapter gives information about specifications, maintenance, troubleshooting, testing and repair of the Kawasaki FJ180V gasoline engine used in the Line Painter 1200. Service and repair parts for the Kawasaki engine used to power the Line Painter 1200 are supplied through your local Toro distributor. Be prepared to provide your distributor with the Toro model and serial number. Most repairs and adjustments require tools which are commonly available in many service shops.
Specifications Item Description Make / Designation Kawasaki, FJ180V, 4–stroke, air–cooled, OHV, single cylinder Bore x Stroke 2.6” x 2.1” (65 mm x 54 mm) Total Displacement 10.9 cu. in. (179 cc) Compression Ratio 8.5:1 Carburetor Float Feed, Fixed Main Jet Mechanical High Idle (No Load) 2800 + 100 RPM Direction of Rotation Counter Clockwise (Facing PTO Shaft) Fuel Unleaded, Automotive Grade Gasoline Fuel Tank Capacity 4 Quart (3.
General Information Fuel Shut–off Valve The fuel shut off valve is positioned in the fuel hose between the fuel tank and the carburetor inlet. It has two positions: CLOSED and OPEN. Turn valve to the closed position when storing or transporting the machine. Rotate valve to the open position before starting the engine. 1 Figure 1 1.
Service and Repairs Cooling System IMPORTANT: The engine that powers the Line Painter 1200 is air–cooled. Operating the engine with dirty or plugged cooling fins or a plugged or dirty blower housing will result in engine overheating and damage. 1 2 IMPORTANT: Never clean engine with pressurized water. Water could enter and contaminate the fuel system. 3 3 2. Remove rewind starter and clean rotating screen (Fig.2). 3.
Fuel Tank 2 3 4 1 3 5 3 6 14 13 3 12 11 7 10 9 RIGHT FRONT 8 Figure 4 1. 2. 3. 4. 5. Fuel tank Fuel tank cap Hose clamp (4 used) Fuel hose Fuel shut off valve Gasoline Engine 6. 7. 8. 9. 10. Fuel hose Engine Screw (2 used) Washer head screw (2 used) Nut (2 used) Page 3 – 6 11. 12. 13. 14.
3. Remove high tension lead from the spark plug and position the lead away from the spark plug. Because gasoline is highly flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot, or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spilled fuel before starting the engine. Store fuel in a clean, safety–approved container and keep cap in place.
Engine 15 11 14 12 16 14 14 17 13 2 1 10 9 14 8 4 3 3 20 to 30 ft–lb (27 to 41 N–m) RIGHT 7 FRONT 6 18 50 to 60 ft–lb (68 to 81 N–m) Loctite #242 250 to 450 in–lb (28 to 51 N–m) 5 19 5 Figure 5 1. 2. 3. 4. 5. 6. 7. Engine Oil drain valve O–ring Drain extension Screw (6 used) Washer head screw (2 used) Nut (2 used) 8. 9. 10. 11. 12. 13. Frame Fuel tank support Washer head screw (2 used) Fuel tank cap Fuel tank Fuel tank bracket Removal (Fig. 5) 1.
7. On the underside of the machine frame (Fig. 7): A. Loosen flange nuts that retain two (2) belt guides to frame. Position belt guides away from engine pulley. B. Loosen idler tension on pump drive belt (lower) and transmission drive bolt (upper) and remove belts from engine pulley. C. Remove four (4) screws that secure engine to machine. 8. Lift the engine from the frame. 9. If necessary, remove cap screw that secures pulley to engine crankshaft. Slide pulley from crankshaft. 8.
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Chapter 4 Electrical System Table of Contents 2 3 4 5 5 6 Electrical System ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . . On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hourmeter (Optional) . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Schematic BLACK HIGH TENSION LEAD BLACK HOUR METER (OPTIONAL) BLACK ENGINE MAGNETO (FLYWHEEL) Electrical System Page 4 – 2 ON/OFF SWITCH BROWN IGNITION COIL ON\OFF SWITCH is open in the ON position.
Special Tools Multimeter The multimeter can test electrical components and circuits for current (amps), resistance (ohms) or voltage. NOTE: Toro recommends the use of a DIGITAL Volt– Ohm–Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode will make sure that excess current is not allowed through the meter. This excess current can cause damage to circuits not designed to carry it.
Troubleshooting CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. For effective troubleshooting and repairs, there must be a good understanding of the electrical circuits and components used on this machine (see Electrical Schematic in this chapter). NOTE: See the Kawasaki FJ180V Service Manual at the end of Chapter 3 – Engine for troubleshooting of engine electrical problems.
Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check). On/Off Switch The on/off switch is used to shut the engine off. When the on/off switch is in the off position, the engine armature is grounded to prevent the engine from running. This switch is located handle panel (Fig. 3).
Hourmeter (Optional) The optional hourmeter available for the Line Painter 1200 uses an inductive pickup wire connected to the spark plug wire to sense when the engine is running. The hourmeter should increase 1/10 of an hour every six (6) minutes of engine running time. The hourmeter uses its own internal battery for operation. The hourmeter battery is not replaceable. NOTE: The hourmeter display is programmed to flash service reminders initially at 50 hours and then every 100 hours thereafter.
Chapter 5 Paint System Table of Contents SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . Paint Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tank Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flush (Water) Tank . . . . . . . . . . . . . . . . . . . . . . . . . Check Valve Service . . . . . . . . . . . . . . . . . . . . . . . . Paint Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Regulator . . . . . . . . . . . . . . . . .
Specifications Item Description Pump Pump Capacity Relief Pressure Diaphragm Pump with 5 Chambers 4 GPM (15.1 LPM) 65 PSI (4.5 Bar) Paint Tank Capacity 12 Gallons (45.4 Liters) Water (Flush) Tank Capacity 2.5 Gallons (9.
Paint System Paint Schematic (OFF) (OFF) (OFF POSITION) Line Painter 1200 Hydraulic Schematic Line Painter 1200 Page 5 – 3 Paint System
Circuit Operation (OFF) (OFF) Line Painter 1200 Paint Circuit Working Pressure Return (Agitation) Suction Flow Paint System Page 5 – 4 Line Painter 1200
Paint Circuit The Line Painter 1200 paint circuit uses a positive displacement diaphragm pump to move paint from the paint tank to the spray nozzle. The spray pump is a self– priming diaphragm pump that has a dry crankcase. The engine drives the spray pump indirectly through pulleys and a V–belt. The spray pump belt is always tensioned by a backside idler pulley so the pump is being rotated whenever the engine is running.
(OPEN) Line Painter 1200 Flush Circuit Working Pressure Return Suction Flow Paint System Page 5 – 6 Line Painter 1200
Flush Circuit The Line Painter 1200 paint circuit uses a positive displacement diaphragm pump to move fluid (water) from the flush (water) tank through the spray system. The spray pump is a self–priming diaphragm pump that has a dry crankcase. When the pump is rotated, the downward stroke of the pump’s diaphragm creates suction to allow fluid (water) to be drawn from the flush tank to the pump via hoses, a one–way check valve, a ball valve (in the flush position) and a 40 mesh screen filter.
Troubleshooting ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
General Information Paint/Flush Lever To prevent paint system pressure spikes, the paint/flush lever should normally be in either the paint mode or the flush mode. It is recommended to use the OFF position only when the engine is not running. 2 If the paint filter is to be cleaned and paint is in the paint tank, turn the paint/flush lever to OFF (engine not running) to prevent paint leakage. 1 3 Figure 1 1. Paint lever (in OFF) 2. Flush mode 3.
Adjustments Spray Pump Relief Valve Adjustment The spray pump used on the Line Painter 1200 is equipped with an adjustable relief valve (Fig. 3). Adjustment of the relief valve is made with a socket head screw on the top of the pump. The end of the socket head screw should be flush with the relief valve housing for correct relief valve adjustment. 2 1 Figure 3 1. Spray pump Paint System Page 5 – 10 2.
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Service and Repairs Paint Tank 144 to 156 in–lb (16.3 to 17.6 N–m) 6 5 192 to 216 in–lb (21.7 to 24.4 N–m) 5 192 to 216 in–lb (21.7 to 24.4 N–m) 4 20 2 7 1 14 8 10 8 11 13 9 10 12 15 3 16 17 19 18 RIGHT FRONT Figure 4 1. 2. 3. 4. 5. 6. 7. Paint tank Nut Tank support Flat washer Jam nut Elbow fitting Tank clamp (2 used) 8. 9. 10. 11. 12. 13. 14. Rubber washer Outlet port Ball valve Recirculation port O–ring Drain valve Elbow fitting 15. 16. 17. 18. 19. 20.
6. Remove two (2) jam nuts that secure tank to ball valve ports (Fig. 5). Locate and retrieve washers (items 4 and 20). 2 1 7. Remove four (4) flange head screws (item 17) that secure tank to tank support. 8. Lift tank from machine. Locate and retrieve rubber washers (item 8) that seal tank to ball valve ports. Discard washers. 3 3 9. If necessary, remove tank lid flange using Figure 6 as a guide. 4 Installation (Fig. 4) 1. Place new rubber washers (item 8) on ball valve ports. Figure 5 1.
Tank Support 6 1 5 2 4 3 RIGHT FRONT Figure 7 1. Handle assembly 2. Flange head screw (4 used) Paint System 3. Chassis 4. Flush tank Page 5 – 14 5. Tank support 6.
To ease service of paint components attached to the tank support, the tank support and handle can be tipped back using the following procedure: 2 1 1. Drain paint tank (see Operator’s Manual). NOTE: The nozzle can be removed from the spray head to allow the flush tank to be emptied faster. 5 2. Clean paint system hoses by operating line painter in the flush mode until the flush tank is empty. 3 3.
Flush (Water) Tank 1 2 14 3 4 5 6 13 7 8 12 9 11 10 RIGHT FRONT Figure 11 1. 2. 3. 4. 5. Paint tank Tank support Cap Cap insert Gasket 6. 7. 8. 9. 10. 11. 12. 13. 14. Stud Flush tank Extension spring Tank support rod Spray pump assembly Elbow fitting Clamp Bushing Flange head screw (4 used) Removal (Fig. 11) 1. Drain paint tank (see Operator’s Manual). 2 NOTE: The nozzle can be removed from the spray head to allow the flush tank to be emptied faster. 2.
5. Unhook extension spring from hole in tank support (Fig. 12). Remove spring and tank support rod from machine. 1 6. Remove flush tank outlet tube from elbow fitting on bottom of ball valve (Fig. 13 and 14) (see Quick Disconnect Fitting in the General Information section). 7. Remove flush tank with outlet tube attached from machine. 2 8. If necessary, remove outlet tube and check valve from flush tank (Fig. 14). Figure 13 1. Ball valve Installation (Fig. 11) 2. Outlet tube location 1.
Check Valve Service The one–way check valve that is positioned between the flush (water) tank and the ball valve (see schematic) prevents paint from entering the flush (water) tank when the paint/flush lever is moved from the paint position to the flush position and while the machine is operated in the flush mode. 1 NOTE: If the flush system is not cleaned after use, diluted paint may cause check valve and associated hoses to become blocked.
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Paint Shutoff Valve 1 PAINT SHUTOFF VALVE 16 18 20 192 to 216 in–lb (21.7 to 24.4 N–m) 17 19 15 14 13 3 4 12 5 11 RIGHT 2 10 FRONT 9 8 7 6 144 to 156 in–lb (16.3 to 17.6 N–m) Figure 18 1. 2. 3. 4. 5. 6. 7. Paint tank Tank support Elbow fitting Paint shutoff valve Flange nut Straight fitting Tee fitting 8. 9. 10. 11. 12. 13. 14. Paint Shutoff Valve Spool (Fig.
Paint Shutoff Valve Removal (Fig. 18) 7. Connect extension spring (item 9) to lever. 1. Drain paint tank (see Operator’s Manual). Operate line painter in the flush mode to clean paint tubes. 8. Connect inlet and outlet hoses to paint shutoff valve (Fig. 19) (see Quick Disconnect Fitting in the General Information section). 2. Park machine on a level surface, stop engine, engage parking brake and remove key from the ignition switch.
Pressure Regulator 144 to 156 in–lb (16.3 to 17.6 N–m) 6 7 8 5 1 2 RIGHT FRONT 3 120 to 132 in–lb (13.6 to 14.9 N–m) 4 Figure 22 1. Pressure regulator 2. Flange head screw (2 used) 3. Straight fitting 7. Bracket 8. Cap screw 4. Tee fitting 5. Tank support 6. Elbow fitting Removal (Fig. 22) 1. Drain paint tank (see Operator’s Manual). Operate line painter in the flush mode to clean paint tubes. 2.
Disassembly (Fig. 24) 1 NOTE: Individual components for the pressure regulator are not available. If pressure regulator is disassembled for cleaning, take care not to damage regulator components. 1. Remove knob from pressure regulator. 3 2 2. Carefully press spring pin from regulator housing. 3. Remove collar, spring and poppet from regulator housing. 4 Assembly (Fig. 24) 1. Assemble regulator in the reverse order of disassembly.
Ball Valve 3 144 to 156 in–lb (16.3 to 17.6 N–m) 4 2 192 to 216 in–lb (21.7 to 24.4 N–m) 192 to 216 in–lb (21.7 to 24.4 N–m) 2 1 5 144 to 156 in–lb (16.3 to 17.6 N–m) 6 24 21 22 23 7 8 84 to 108 in–lb (9.5 to 12.2 N–m) 9 20 10 14 13 19 18 11 12 84 to 108 in–lb (9.5 to 12.2 N–m) 15 16 RIGHT FRONT 17 Figure 25 1. 2. 3. 4. 5. 6. 7. 8. Paint tank Jam nut Elbow fitting Flat washer Slotted washer Rubber washer Outlet port Ball valve bracket 9. 10. 11. 12. 13. 14. 15. 16.
NOTE: Individual components for the ball valves are not available. 10.Install flush tank (see Flush (Water) Tank Installation in this section). NOTE: Ball valve nut threads have thread sealant applied during initial assembly. Nut removal may be difficult. 11. Secure high tension lead to spark plug. 1 10.If needed, disassemble ball valve using Fig. 27 as a guide. 3 Installation (Fig. 25) 1. If ball valves were disassembled, assemble ball valves using Fig. 27 as a guide. Torque nut 45 to 55 in–lb (5.
Spray Pump Drive Belt 17 16 15 14 1 13 2 3 12 4 11 5 6 8 7 9 10 Figure 29 1. 2. 3. 4. 5. 6. Engine pulley Lock nut Idler pulley Shoulder screw Extension spring Idler bracket 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Pivot washer Cap screw Lock nut Spray pump Pump drive belt Pump pulley Set screw Square key Flat washer Lock washer Cap screw Removal (Fig. 29) Installation (Fig. 29) 1. Drain paint tank (see Operator’s Manual). 1. Position pump drive belt to engine pulley. 2.
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Spray Pump 14 1 2 13 12 11 3 RIGHT 4 10 9 FRONT 5 6 8 7 Figure 30 1. 2. 3. 4. 5. Tank support Flange head screw (4 used) Spray pump assembly Flange nut (3 used) Pulley 6. 7. 8. 9. 10. Chassis Cap screw (3 used) Flush tank Paint tank 3. Remove spray pump drive belt (see Spray Pump Drive Belt Removal in this section). Removal (Fig. 30) 1. Drain paint tank (see Operator’s Manual). 2. Park machine on a level surface, stop engine, engage parking brake and remove key from the ignition switch.
5. Tip tank support to gain access to spray pump (see Tank Support in this section). 3 6. Disconnect suction and pressure hoses from spray pump fittings (Fig. 31). 7. Remove three (3) flange nuts (item 4) and cap screws (item 12) that secure spray pump to chassis. 4 8. Lift spray pump assembly from machine. Installation (Fig. 30) 1 1. Position spray pump to machine chassis. Secure pump to chassis with three (3) flange nuts (item 4) and cap screws (item 12). 2.
Spray Pump Service 25 to 30 in–lb (2.8 to 3.4 N–m) 15 14 25 to 30 in–lb (2.8 to 3.4 N–m) 8 11 10 8 16 13 12 17 1 2 3 8 9 4 7 5 6 Figure 32 1. 2. 3. 4. 5. 6. Pump head Check valve kit Wobbler plate/diaphragm assembly Gasket Pump endbell Bearing 7. 8. 9. 10. 11. 12. Straight fitting O–ring Filter cover O–ring Filter (40 mesh) Flat washer (10 used) Disassembly (Fig. 32) 1. Remove two (2) socket head screws and lock washers that secure spray pump to pump drive housing (Fig. 34).
B. Slide drive shaft and bearings into housing. 8. If necessary, remove fittings in filter (item 7) and/or pump head (item 16) by sliding retainer and pulling fitting from housing. Remove and discard o–rings (item 8). 1. If paint has dried on internal pump parts, components or complete pump replacement will most likely be required. IMPORTANT: Do not attempt to clean internal pump components with solvents as component damage will occur. 2.
Spray Head 1 21 17 2 18 168 to 216 in–lb (19 to 24.4 N–m) 3 Saf–T–Lok PTFE Pipe Sealant 19 4 16 20 5 5 6 7 18 8 9 8 17 15 10 11 14 Saf–T–Lok PTFE Pipe Sealant 12 13 144 to 156 in–lb (16.3 to 17.6 N–m) Figure 36 1. 2. 3. 4. 5. 6. 7. Hose Hose clamp Barb fitting Nozzle tube Wing nut Nozzle bracket Knob Paint System 8. 9. 10. 11. 12. 13. 14. Shield Nozzle bracket Diaphragm nozzle Spray nozzle Seat gasket Adapter cap Cap screw (3 used) Page 5 – 32 (Rev. A) 15. 16. 17. 18. 19. 20. 21.
Disassembly (Fig. 36) 1. Operate line painter in the flush mode to clean paint tubes. 1 2. Park machine on a level surface, stop engine, engage parking brake and remove key from the ignition switch. Remove high tension lead from the spark plug and position the lead away from the spark plug. 2 3. Remove spray head components as needed using Figures 36 and 37 as guides. 5 6 3 4 Assembly (Fig. 36) 1. Assemble spray head using Figures 36 and 37 as guides.
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Chapter 6 Chassis and Controls Table of Contents Chassis and Controls SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Traction Drive Cable . . . . . . . . . . . . . . . . . . . . . . . . . 3 Front Castor Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 6 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications Item Description Tire Pressure Front Castor Tire Rear Tire Chassis and Controls 18 to 20 PSI (1.2 to 1.4 Bar) 12 to 15 PSI (0.8 to 1.
Adjustments Traction Drive Cable 1. Park machine on a level surface, stop engine, engage parking brake and remove key from the ignition switch. Remove high tension lead from the spark plug and position the lead away from the spark plug. 2 4 2. Make sure that traction lever on handle is released. 3. Adjust location of traction cable jam nuts so that traction cable spring is stretched .120” to .250” (3.0 to 6.4 mm) from it’s relaxed state. 5 4.
Front Castor Fork 4 5 3 RIGHT 2 FRONT 1 Figure 2 1. Front castor wheel 2. Socket head screw (2 used) 3. Lock washer (2 used) 4. Castor plate If the Line Painter 1200 does not follow a straight line when the castor detent is engaged, front castor fork adjustment is necessary. Adjustment 1. Park machine on a level surface, stop engine, engage parking brake and remove key from the ignition switch. Remove high tension lead from the spark plug and position the lead away from the spark plug. 5.
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Service and Repairs Wheels RIGHT FRONT ANTISEIZE LUBRICANT 10 8 9 6 11 4 3 7 5 1 2 Figure 4 1. 2. 3. 4. Front castor wheel Bushing Cap screw Castor fork Chassis and Controls 5. 6. 7. 8. Lock nut E–ring Washer Rear wheel Page 6 – 6 9. Square key 10. Thrust washer 11.
Removal (Fig. 4) 1. Park machine on a level surface, stop engine, engage parking brake and remove key from the ignition switch. Remove high tension lead from the spark plug and position the lead away from the spark plug. 4 1 5 2. Raise machine so that wheel to be removed is off the ground. Support machine to prevent it from shifting during wheel removal. 2 3. To remove front wheel: 3 A. Remove lock nut (item 5) and cap screw (item 3) that secure wheel to castor fork. 6 B.
Brake Cable 2 Note: Console shown removed from handle for clarity 1 7 8 3 6 4 5 Brake Cable Attachment Point RIGHT FRONT Figure 6 1. Brake lever 2. Knob 3. Compression spring 7. Hairpin 8. Flange nut 4. Shoulder screw 5. Handle assembly 6. Brake cable Removal (Fig. 6) 1. Park machine on a level surface, stop engine and remove key from the ignition switch. Remove high tension lead from the spark plug and position the lead away from the spark plug.
2. Connect brake cable to brake lever on handle (Fig. 6): 4. Secure high tension lead to spark plug. A. Slide cable end onto brake lever and secure with hair pin. B. Secure cable to handle assembly with jam nut. 3. Connect brake cable to brake lever on transaxle (Fig. 7): 1 2 A. Connect cable spring to brake lever. B. Position cable to chassis bracket. 3 C. Tighten cable jam nuts enough to prevent cable spring hook from coming off transaxle brake lever.
Castor Release Cable 2 3 4 1 5 9 6 8 7 6 Figure 8 1. Castor release lever 2. Rubber bumper 3. Traction lever Removal (Fig. 8) 1. Park machine on a level surface, stop engine, engage parking brake and remove key from the ignition switch. Remove high tension lead from the spark plug and position the lead away from the spark plug. 2. Disconnect castor release cable from castor release lever on machine handle: A. Loosen jam nut that secures cable to handle assembly. B.
3. Connect castor release cable to castor release detent under front of machine (Figs. 9 and 10): 2 A. Secure cable clevis to castor release detent with clevis pin and hair pin. B. Position cable to chassis bracket. 4 C. Tighten cable jam nuts to allow castor detent to completely disengage from front castor when castor release lever on handle is pulled against handle. 3 1 4 D. Make sure that cable boot is positioned over end of cable. Figure 9 4. Secure high tension lead to spark plug. 1.
Traction Drive Cable 1 10 2 3 4 9 8 7 6 4 5 Figure 11 1. 2. 3. 4. Traction lever Flat washer Cap screw Flange bushing 8. Bushing (2 used) 9. Bushing 10. Castor release lever 5. Traction drive cable 6. Hair pin 7. Flange nut Removal (Fig. 11) 1. Park machine on a level surface, stop engine, engage parking brake and remove key from the ignition switch. Remove high tension lead from the spark plug and position the lead away from the spark plug. 2.
2. Connect traction drive cable to traction lever on machine handle: A. Slide cable end onto traction lever and secure with hair pin. 2 3 B. Secure cable to handle assembly with jam nut. C. Make sure that cable boot is positioned over end of cable. 3. Connect traction drive cable to traction idler bracket under machine (Fig. 12): 1 A. Connect cable spring to idler bracket. B. Position cable to chassis bracket. Figure 12 C.
Paint Control Cable 8 9 1 2 3 3 4 5 7 6 Figure 13 1. Paint control lever 2. Bushing 3. Bushing 7. Rubber bumper 8. Cap screw 9. Flat washer 4. Flange nut 5. Hair pin 6. Paint control cable Removal (Fig. 13) 1. Park machine on a level surface, stop engine, engage parking brake and remove key from the ignition switch. Remove high tension lead from the spark plug and position the lead away from the spark plug. 3. Disconnect paint control cable from paint shutoff valve (Fig. 14): A.
Installation (Fig. 13) 1. Position paint control cable to machine. 2. Connect paint control cable to paint control lever on machine handle: 4 2 A. Slide cable end onto paint control lever and secure with hair pin. 1 B. Secure cable to handle assembly with jam nut. 3 C. Make sure that cable boot is positioned over end of cable. 3. Connect paint control cable to paint shutoff valve (Figs. 14): A. Secure cable clevis to shutoff valve lever with clevis pin and hair pin. B.
Front Castor Fork 14 13 12 9 11 10 9 8 7 6 4 5 3 RIGHT FRONT 1 2 Figure 16 1. 2. 3. 4. 5. Castor wheel Bushing Socket head screw (2 used) Lock washer (2 used) Lock nut 6. 7. 8. 9. 10. 11. 12. 13. 14. Castor fork Cap screw Castor plate Bushing Grease fitting Removal (Fig. 16) 1. Park machine on a level surface, stop engine, engage parking brake and remove key from the ignition switch. Remove high tension lead from the spark plug and position the lead away from the spark plug. 2.
Installation (Fig. 16) 6. Carefully lower machine to ground. 1. If removed, install bushing(s) (item 9) into chassis. 7. Lubricate grease fitting for castor fork. 2. If removed, install castor plate to castor fork with two (2) socket head screws (item 3) and lock washers (item 4). 8. Secure high tension lead to spark plug. 3. Coat stem of castor fork with grease. Slide fork into chassis. 4. Position wave washer (item 11) and rebound washer (item 12) to top of castor fork.
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Chapter 7 Traction Drive System Table of Contents Traction Drive System SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 2 Traction Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Shift Lever and Linkage . . . . . . . . . . . . . . . . . . . . . . 4 Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Transaxle Service . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs Traction Drive Belt 2 3 4 5 6 1 7 8 13 12 9 10 10 FRONT 11 RIGHT 10 Figure 1 1. 2. 3. 4. 5. Traction drive belt Idler pulley Lock nut Shoulder bolt Idler bracket 6. 7. 8. 9. Removal (Fig. 1) 1. Park machine on a level surface, stop engine and remove key from the ignition switch. Remove high tension lead from the spark plug and position the lead away from the spark plug. 2.
2. Position traction drive belt to idler pulley and bracket making sure that belt is placed between pulley and guide on bracket (Fig. 2). Tighten cap screw (item 12) and lock nut (item 3) to secure idler pulley to idler bracket. 2 3. Tension the traction drive belt by depressing the traction drive lever operator control. Rotate belt guides to allow from .060” to .130” (1.5 to 3.3 mm) clearance between guide and tensioned traction drive belt. Tighten lock nuts to secure guides in place. 4.
Shift Lever and Linkage Note: Console shown removed from handle for clarity 2 1 3 8 4 7 11 5 10 7 4 6 12 9 6 4 7 RIGHT 7 4 15 FRONT 6 13 14 6 Figure 3 1. 2. 3. 4. 5. Handle Console Knob Nylon washer Console shift lever Traction Drive System 6. 7. 8. 9. 10. Bushing Hair pin Clevis pin Shift lever (on transaxle) Shift link Page 7 – 4 11. 12. 13. 14. 15.
Disassembly (Fig. 3) Assembly (Fig. 3) 1. Park machine on a level surface, stop engine, apply parking brake and remove key from the ignition switch. Remove high tension lead from the spark plug and position the lead away from the spark plug. 1. Assemble shift linkage components using Figure 3 as a guide. 2. Disassemble shift linkage components as needed using Figure 3 as a guide. 2.
Transaxle 4 RIGHT 14 8 13 FRONT 9 7 16 15 16 5 3 12 10 11 4 15 ANTISEIZE LUBRICANT 5 6 6 1 3 ANTISEIZE LUBRICANT 2 ANTISEIZE LUBRICANT Figure 4 1. 2. 3. 4. 5. 6. Transaxle assembly Flange nut (4 used) Thrust washer Wheel and tire Square key Spacer 7. 8. 9. 10. 11. Brake return spring Carriage screw (4 used) Cap screw Lock washer Spacer Removal (Fig. 4) 1. Park machine on a level surface, stop engine and remove key from the ignition switch.
Installation (Fig. 4) 1. Chock front castor wheel. Raise machine so that rear of machine is off the ground. Support machine to prevent it from shifting during transaxle installation. 2. If drive pulley was removed from transaxle input shaft, apply antiseize lubricant to input shaft. Position woodruff key (not shown) in input shaft keyslot. Slide drive pulley onto shaft and secure with snap ring (item 14). 7. Connect brake return spring (item 7) to brake lever on transaxle. 8.
Transaxle Service 36 35 30 to 40 in–lb (3.4 to 4.5 N–m) 34 19 1 240 to 300 in–lb (27.1 to 33.9 N–m) 2 3 5 4 6 33 11 7 32 39 40 41 37 38 42 8 43 44 45 49 10 31 46 48 11 12 13 47 19 50 9 11 14 30 29 28 51 12 27 16 15 FRONT 17 RIGHT 26 52 25 21 24 53 54 18 23 22 55 56 21 20 54 19 53 58 57 56 26 68 50 66 65 63 62 60 160 to 200 in–lb (18.1 to 22.
Figure 5 (Continued) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. Screw Detent cover Detent spring (2 used) Detent ball (2 used) Cap plug Shifter boot Screw (16 used) Upper housing Shifter Retaining ring Shim washer Plain washer Washer Bearing Woodruff key Input shaft Bevel pinion gear (12T) Retaining ring Flange bearing Washer Spacer Spur gear (31T) Spur gear (23T) 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46.
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